Direct Lithium Extraction Extends to Battery Recycling

Direct lithium extraction (DLE) is a concept making big inroads in lithium mining due to its process efficiencies and sustainability benefits. Now Les Ulis, France-based Adionics is announcing a new version of the company’s Flionex lithium-extraction media that can now successfully recover high-purity lithium from battery black mass, the shredded remains of lithium-ion batteries in the recycling process, and returning it to battery production.

According to Adionics, the innovations now made possible in this development include:

“The new version of Flionex represents a significant leap forward in promoting a truly circular economy for lithium-ion batteries,” says Gabriel Toffani, Adionics CEO. “Combining versatility with the ability to process battery black mass positions Adionics at the forefront of sustainable lithium production. Addressing and solving the challenges of lithium extraction during recycling not only reduces waste but creates a sustainable cycle for one of the most critical components of modern energy storage.”

Adionics CEO Gabriel Toffani ADIONICS

Less waste, lots more lithium from brine and batteries

Chemical Engineering, in a technical article earlier this year, describes typical lithium extraction technologies as achieving between 30% and 60% yields from brine. It calls Adionics’s Flionex a “proprietary thermal-swing liquid-liquid deionization process” enabling up to 99% lithium recovery with little co-extractants. “When raw brine is brought into contact with Flionex, all lithium is extracted, little sodium and little calcium are co-extracted, while other elements, such as potassium, boron, magnesium and sulfates, are rejected,” the article describes.

“The loaded medium is then washed with cool water to remove the undesired sodium and calcium, which are partially desorbed, while lithium remains in the organic phase. Finally, the loaded Flionex is contacted with heated demineralized water. Only the lithium and chloride are released into the aqueous phase, forming a concentrated stream of LiCl. The newly regenerated Flionex is sent back to the extraction phase.”

“It is important to highlight that Adionics’ process does not require any chemical input throughout the process besides a limited amount of fresh water. This technology guarantees lithium recovery up to 99% with purity up to 99%,” says François-Michel Colomar, an engineer and Adionics’ head of external relations. Furthermore, he notes, the extraction technology can be adapted to recover lithium from different brine sources, including geothermal sites and industrial effluents, in addition to battery-recycling facilities.

Notably, the selectivity makes the process suitable for magnesium- and sulfate-rich brines, which cannot be processed using typical lithium-extraction methods. The depleted brine can be reinjected to the source without any pre-treatment, since the technology does not change brine pH, says Colomar.

Testing success

The company recently completed extensive testing of the technology (over 1,500 h) at a pilot plant in Chile’s Salar de Atacama, producing 99% pure LiCl. The tests showed stable operation with a wide range of brine concentrations at fluctuating temperatures. The company has also built a 250-ton/yr demonstration plant, which is to be installed in Argentina, and initial engineering work is underway for a 20,000-ton/yr commercial-scale plant.